Oops! How would you fix this?

[Ba11erz]

Currently in a jam and would hate to think my momentum on replacing my injectors has come to a screeching halt.

Any suggestions on how I can fix this break in my plenum?


and...


and finally...


I was thinking of using a mig weld with aluminum attachment. Need help fast!

[robomatic12]

I would weld it, if possible. That would be the best option before trying any epoxies.

[Ba11erz]

I would weld it, if possible. That would be the best option before trying any epoxies.

Gotit! Busy day tomorrow finding an open welding shop. We'll see how it goes and thanks robomatic12.

[a.p.barron]

Yikes! How did you manage to do that?

[Ba11erz]

Yikes! How did you manage to do that?

There may have been some over spray when I was painting the plenum. Somehow it created a tight fit; but I thought the new pcv was just being stubborn. The next time I will ensure the threads are clean of residue. On a positive note, I managed to get complete everything underneath the plenum, so all I have is wiring, plumbing, and dual walbro install.

[marty1mc]

Next time you run into this, back it out and work it a quarter to half a turn at a time. This will allow the gunk to clear. But, you should never allow that to get where it can enter the motor. Masking it off is the best solution (or in this case, leave the old ones in place while painting...

[car nut]

Make sure it's an experienced welder who's welded cast before, it's very difficult from what I've heard.

[GerryO]

After talking to the welder, you may decide to cut v-shaped troughs, following the crack lines, remove the PCV valve, find a way clamp things during welding and chase the threads with a tap before re-assembly.

Then you may also be able to remove some weld material afterward to hide the repairs. I used Teflon tape on the ends of mine and they don't need to be so tight, plus threading them in less makes them "longer" for connecting the hoses to them.

Maybe you can find someone who normally works with aluminum bicycle frames (lighter/thinner gauge material).

Looks like you are doing the throttle body coolant/heating by-pass.